Lamborghini Cutting the Cost of Carbon-Fiber Parts

The cost of conventional carbon fiber is twofold—material and labor. Little can be done about the cost of raw materials. Simplifying production is Lamborghini's new technique called Forged Composite. It was demonstrated in the production of the Sesto Elemento concept car and is expected to be heavily used on the next Gallardo. Although Forged Composite is not as light as the other methods, it is easier to produce.

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The process starts with 1–2 in. lengths of scrap carbon fiber. The material is matted together in a long strip and then rolled up like an unbaked cinnamon bun—tacky with resin. It's then placed in a metal mold, squeezed and heated. Out comes a finished part, such as this badge.

Unlike other methods, this one offers minimal control of fiber direction. Therefore, to guarantee a certain strength, excess material is necessary, which makes the piece heavier than it needs to be but still lighter than aluminum. Lamborghini is working to optimize the process, so it's only a matter of time before the company starts stamping out carbon-fiber chassis in earnest.